WO2017173921A1 - 一种连续半固态压铸生产方法及生产系统 - Google Patents

一种连续半固态压铸生产方法及生产系统 Download PDF

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Publication number
WO2017173921A1
WO2017173921A1 PCT/CN2017/077539 CN2017077539W WO2017173921A1 WO 2017173921 A1 WO2017173921 A1 WO 2017173921A1 CN 2017077539 W CN2017077539 W CN 2017077539W WO 2017173921 A1 WO2017173921 A1 WO 2017173921A1
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Prior art keywords
solid
semi
modifier
slurry
die casting
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PCT/CN2017/077539
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English (en)
French (fr)
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任怀德
张莹
王继成
李谷南
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珠海市润星泰电器有限公司
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Application filed by 珠海市润星泰电器有限公司 filed Critical 珠海市润星泰电器有限公司
Priority to JP2018545486A priority Critical patent/JP6651644B2/ja
Priority to EP17778585.4A priority patent/EP3360623B1/en
Priority to KR1020187025254A priority patent/KR102133660B1/ko
Publication of WO2017173921A1 publication Critical patent/WO2017173921A1/zh
Priority to US15/874,858 priority patent/US10682693B2/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/32—Controlling equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007—Semi-solid pressure die casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D1/00—Treatment of fused masses in the ladle or the supply runners before casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
    • C22B9/10—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals with refining or fluxing agents; Use of materials therefor, e.g. slagging or scorifying agents
    • C22B9/103—Methods of introduction of solid or liquid refining or fluxing agents

Definitions

  • the invention relates to the field of semi-solid die casting production, in particular to a continuous semi-solid die casting production method and production system.
  • the semi-solid die-casting technology developed in the early 1970s has profoundly changed the traditional die-casting method.
  • domestic and foreign researchers have proposed a number of semi-solid metal paste preparation processes, such as mechanical agitation, electromagnetic stirring, controlled solidification, strain activation, powder metallurgy and other methods.
  • many semi-solid metal pulping methods exist the solid-liquid ratio of the semi-solid slurry is difficult to control, and the prepared semi-solid slurry has coarse spherical crystals and low roundness. These pulping methods are affected by the efficiency of the pulping equipment and the quality stability of the semi-solid slurry. They are not extended to the actual continuous die casting production in the factory, and are still in the laboratory research stage.
  • Semi-solid production in the die casting industry is subject to pulping equipment, pulping processes and semi-solid slurry quality.
  • the pulping process of the above pulping process is complicated, the pulping efficiency is low, and the solid content of the slurry is unstable, so that the general pulping process cannot be used for continuous batch die casting production.
  • the semi-solid slurry preparation method and the continuous die-casting process of the invention solve the problem of high-efficiency and continuous production of semi-solid die-casting production.
  • the present invention provides a continuous semi-solid die casting production method and production system, aiming at improving semi-solid slurry preparation efficiency, stabilizing semi-solid slurry quality, and solving semi-solid continuous die casting production problems.
  • the continuous semi-solid die casting production method provided by the invention comprises:
  • the semi-solid die casting machine is controlled to perform semi-solid die casting.
  • the preparation of the semi-solid slurry for controlling the deterioration agent preparation apparatus for producing the solid deterioration agent and conveying the solid modification agent to the semi-solid slurry preparation apparatus comprises the following steps:
  • the sealing cover is controlled to be locked, and the resistance furnace is controlled to be heated to make the modifier ingot become a liquid modifier at a temperature preset temperature, and the metal mold is controlled to preheat and maintain the first preset temperature.
  • the agent is output to the solid state modifier transfer device through a solid state modifier transfer device, the liquid preset temperature is 650 to 700 degrees Celsius, and the first preset temperature ranges from 180 to 240 degrees Celsius.
  • the mass of the solid state modifying agent in the preparation vessel having the liquid slurry delivered to the semi-solid slurry preparation apparatus is 0.5 to 1.5% of the mass of the liquid slurry.
  • the mass of the solid state modifier in the preparation vessel having the liquid slurry delivered to the semi-solid slurry preparation apparatus was 1% of the mass of the liquid slurry.
  • the solid modifier is hollow hemispherical granules each having a weight of 10 to 20 grams.
  • the controlling the semi-solid slurry preparation device for producing the semi-solid slurry comprises: controlling the air-cooled mechanical stirring device to perform stirring in the preparation container, stirring the preset time length at a preset rotation speed, and measuring by the hollow stirring rod
  • the temperature device obtains the temperature of the semi-solid slurry, and controls the preparation temperature of the preparation container to maintain the temperature of the semi-solid slurry at a second preset temperature; the 200-1000 rpm, the pre- The duration is 10 to 25 seconds, and the second preset temperature is 595 to 605 degrees Celsius.
  • the preset rotational speed is 800 rpm
  • the preset duration is 20 seconds
  • the second preset temperature is 605 degrees Celsius.
  • the continuous semi-solid die casting production system comprises: a modifier preparation device, a semi-solid slurry preparation device, a semi-solid die casting machine, a central controller;
  • the central controller is configured to control the modifier preparation device to produce a solid modifier and deliver the solid modifier to a preparation vessel having a liquid slurry of a semi-solid slurry preparation device; and control the preparation of the semi-solid slurry
  • the apparatus produces a semi-solid slurry and delivers the semi-solid slurry to a semi-solid die casting machine; the semi-solid die casting machine is controlled for semi-solid die casting.
  • the modifier preparation device comprises a resistance furnace, a sealing cover, a riser tube, a metal mold, a hydraulic device, a hydraulic device, a solid state modifier conveying device;
  • the central controller is configured to control a modifier preparation device to produce a solid modifier and transport the solid modifier according to the following method: after the modifier ingot is added to the resistance furnace, control the sealing cover to lock, and control the resistance furnace Heating to make the modifier ingot into a liquid modifier at a temperature preset temperature of the liquid, controlling the mold to preheat to and maintaining the first preset temperature, controlling the hydraulic device to close the metal mold, and controlling the liquid to control the liquid Injecting the modifier into the metal mold, controlling the hydraulic device to open the metal mold after generating the solid modifier, and outputting the generated solid modification agent to the solid modifier transfer device through the solid modifier transfer device, the liquid preset
  • the temperature is 650 to 700 degrees Celsius, and the first predetermined temperature ranges from 180 to 240 degrees Celsius.
  • the semi-solid slurry preparation device comprises a hollow stirring rod with a built-in copper tube and a preparation container; and the hollow stirring rod is provided with a temperature measuring device;
  • the central controller is configured to control the air-cooled mechanical stirring device to perform stirring in the preparation container, stir the preset time length at a preset rotation speed, and obtain the semi-solid slurry by the temperature measuring device of the hollow stirring rod. Temperature, and controlling the preparation temperature of the preparation vessel to maintain the temperature of the semi-solid slurry at a second preset temperature, the 200-1000 rpm, the preset duration being 10-25 seconds, The second preset temperature is 595-605 degrees Celsius.
  • the liquid slurry By adding a solid modifier in the liquid slurry, while controlling the percentage of addition of the modifier and the relative temperature of the modifier and the liquid slurry, the liquid slurry can be rapidly cooled, and the solid modifier is melted and decomposed during the stirring process. A large amount of solid nucleation is formed, so that the dendrites broken by stirring rapidly form a fine round spherical crystal structure, and the content of the slurry solid in the finally formed semi-solid slurry is increased and stabilized at about 42 to 50%. .
  • the solid content makes the spherical crystals fine and round, which solves the problem of low solid content in the preparation process of the conventional semi-solid slurry, thereby improving the efficiency of semi-solid pulping and stabilizing the quality of the semi-solid slurry.
  • Figure 1 is a structural view of a continuous semi-solid die casting production system of the present invention
  • Figure 2 is a flow chart of the continuous semi-solid die casting production method of the present invention.
  • FIG. 3 is a metallographic structure diagram of a semi-solid slurry produced using the method of the present invention.
  • central controller 1 modifier preparation device 2
  • resistance furnace 201 sealing cover 202
  • sealing cover 202 riser tube 203
  • metal mold 204 hydraulic device 205
  • solid state modifier delivery device 206 solid state modifier delivery device 206
  • semi-solid slurry preparation device 3 An air-cooled mechanical stirring device 301, a container 302, and a semi-solid die casting machine 4.
  • FIG. 1 is a structural view of a continuous semi-solid die casting production system of the present invention, the production system comprising: a central controller 1 and a modifier preparation device 2, a semi-solid slurry preparation device 3, and a half, each electrically connected to a central controller. Solid die casting machine 4.
  • the central controller 1 controls the entire production process, and each process action completes the continuous die-casting production through the numerical control program and the corresponding inductive position switch automatic cycle.
  • the central controller 1 controls the modifier preparation apparatus 2 to produce a solid modifier and delivers the solid modifier to the preparation vessel having the liquid slurry of the semi-solid slurry preparation apparatus 3; and controls the semi-solid slurry preparation apparatus 3 to produce the semi-solid slurry And feeding the semi-solid slurry to the semi-solid die casting machine 4; controlling the semi-solid die casting machine 4 for semi-solid die casting.
  • the modifier preparation apparatus 2 includes a resistance furnace 201, a sealing cover 202, a riser tube 203, a metal mold 204, a hydraulic device 205, and a solid state modifier conveying device 206.
  • the central controller 1 controls the modifier preparation apparatus 2 to produce a solid modifier and transports the solid modifier according to the following method: after the modifier ingot is added to the resistance furnace 201, the sealing cover 202 is controlled to be locked, and the resistance furnace 201 is controlled to heat the modifier.
  • the ingot becomes a liquid tempering agent whose temperature is a liquid preset temperature
  • the control metal mold 204 is preheated to and maintains the first preset temperature
  • the control hydraulic device 205 closes the metal mold 204
  • the liquid elevating tube 203 is controlled to inject the liquid modificating agent into the metal mold 204.
  • the hydraulic device 205 is controlled to open the metal mold 204, and the generated solid-state modificator is output to the solid-state modificator transport device through the solid-state modificator transport device 206, wherein the liquid preset temperature is 650-700 degrees Celsius, A preset temperature range is 180 to 240 degrees Celsius.
  • the metal mold 204 includes an upper film chamber and a lower film chamber. After the mold 204 is controlled by the hydraulic device 205, the upper mold cavity can be transported to the pulping area under the transfer of the lead screw, and the solid modifier is transferred to the solid modifier. Conveying device 206.
  • the semi-solid slurry preparation apparatus 3 includes an air-cooled mechanical stirring apparatus 301 and a preparation container 302; a temperature measuring device is disposed in the hollow stirring rod 301.
  • the air-cooled mechanical stirring device 301 comprises a hollow stirring rod with a built-in copper tube. When the stirring rod rotates, the compressed air of a certain flow rate and pressure exchanges heat with the aluminum liquid indirectly, and the aluminum liquid cools down. Among them, when the air-cooled mechanical stirring device is provided, it is preferable to set the cooling air pressure to 3.5 to 4.5 KPa and the compressed air flow rate to 10 to 30 L/min.
  • the central controller 1 controls the air-cooled mechanical stirring device 301 to stir in the preparation container, stirs the preset time length at a preset rotation speed, obtains the temperature of the semi-solid slurry through the temperature measuring device of the hollow stirring rod, and controls the preparation temperature of the preparation container.
  • the temperature of the semi-solid slurry is maintained at the second predetermined temperature, and the variation range of the second preset temperature is maintained within a deviation range of ⁇ 3 degrees Celsius.
  • the preset speed is 200 to 1000 rpm
  • the preset duration is 10 to 25 seconds
  • the second preset temperature is 595-605 degrees Celsius.
  • Figure 2 is a flow chart of a continuous semi-solid die casting production process. The method includes: controlling by the central controller to perform the following:
  • Step 1 controlling the modifier preparation device to produce a solid modification agent and conveying the solid modification agent to the preparation container with the liquid slurry of the semi-solid slurry preparation device;
  • Step 2 controlling the semi-solid slurry preparation device to produce the semi-solid slurry and conveying the semi-solid slurry to the semi-solid die casting machine;
  • Step 3 Control the semi-solid die casting machine to perform semi-solid die casting.
  • step 1 after the modifier ingot is added into the resistance furnace, the sealing cover is controlled to be locked, and the resistance furnace is heated to make the modifier ingot become a liquid modifier at a temperature preset temperature, and the metal mold is preheated to maintain the first preheating.
  • Set temperature control
  • the hydraulic device opens the metal mold, controls the liquid lift pipe to inject the liquid modification agent into the metal mold, controls the hydraulic device to close the metal mold, controls the hydraulic device to open the metal mold after generating the solid modification agent, and passes the generated solid modification agent through the solid modification agent conveying device. (Can be a flow cell) output to a solid state modifier transfer device.
  • the liquid preset temperature is 650-700 degrees Celsius, preferably 680 degrees Celsius, and the first preset temperature ranges from 180-240 degrees Celsius.
  • the modifier particles Preheating the control metal mold to 180-240 degrees Celsius, the modifier particles can be maintained at 80-120 degrees Celsius, and the hollow hemispherical modifier particles added during pulping can be easily melted to form a solid nucleus with a temperature of 80.
  • the tempering agent particles of ⁇ 120 degrees can achieve the purpose of rapid cooling during the pulping process.
  • the mass of the solid state modifying agent in the preparation vessel having the liquid slurry delivered to the semi-solid slurry preparation apparatus is 0.2 to 1.5% by mass of the liquid slurry.
  • the amount of modifier added has a certain influence on the roundness and solid content of the spherulites, as shown in Table 1.
  • the solid metamorphic agent is hollow hemispherical particles each having a weight of 10 to 20 grams.
  • controlling the semi-solid slurry preparation equipment to produce the semi-solid slurry comprises: controlling the air-cooled mechanical stirring equipment in the system Stirring in the preparation vessel, stirring the preset length at a preset speed, obtaining the temperature of the semi-solid slurry through the temperature measuring device of the hollow stirring rod, and controlling the preparation temperature of the preparation vessel to maintain the temperature of the semi-solid slurry in the second pre-preservation Set the temperature; the preset speed is 200 to 1000 rpm, the preset time is 10 to 25 seconds, and the second preset temperature is 595-605 degrees Celsius.
  • the stirring rod rotation speed and stirring time have a certain influence on the spherical crystal structure and the energy performance of the semi-solid casting, as shown in Table 2.
  • the nucleus while increasing the convection intensity, can promote the uniform distribution of the internal temperature field and the concentration field of the supercooled alloy melt; (b) when the stirring speed is small, the dendrites and the stirring blades, the dendrites and the walls, and the branches The number and intensity of collisions between the crystal and the dendrites are insufficient, and only some of the dendrites are broken.
  • the impact strength and frequency will increase greatly, which is beneficial to the dendrite arm breaking, and at the same time, it is beneficial to rounding at the sharp corners of the granular grains, thereby transforming into nearly spherical grains.
  • the violent stirring speed will cause the alloy melt to be severely entangled, resulting in more pore defects in the structure, which is not conducive to the performance of the formed part.
  • Figure 3 is a metallographic structure diagram of a semi-solid slurry produced in the present invention.
  • the liquid slurry By adding a solid modifier in the liquid slurry, while controlling the percentage of addition of the modifier and the relative temperature of the modifier and the liquid slurry, the liquid slurry can be rapidly cooled, and the solid modifier is melted and decomposed during the stirring process. A large amount of solid nucleation is formed, and the dendrites broken by stirring rapidly form a fine round spherical crystal structure, and the content of the slurry solid in the finally formed semi-solid slurry is increased and stabilized at about 42 to 50%.
  • the pulping time is shortened, the solid content of the slurry is increased, the spherical crystal is refined and rounded, and the problem of low solid content in the preparation process of the conventional semi-solid slurry is solved, thereby improving the efficiency of semi-solid pulping and stabilizing.
  • the quality of the semi-solid slurry is improved.
  • the continuous semi-solid die casting production method of the invention shortens the pulping time, improves the solid content of the slurry, refines and rounds the spherical crystal, and solves the problem that the solid content of the conventional semi-solid slurry preparation process is low, thereby improving the problem.
  • the semi-solid pulping efficiency stabilizes the quality of the semi-solid slurry; the production system realizes the linkage cycle operation of the three steps of solid modifier preparation, semi-solid slurry preparation and semi-solid slurry die casting, realizing semi-solid die casting
  • the production of integrated equipment is automatically and stably produced.
  • the internal quality of the semi-solid die-casting parts produced is stable, the qualification rate is improved, and the production cost is lowered.
  • the continuous cycle of integrated equipment for semi-solid die-casting has opened up a new model for semi-solid die-casting production, providing new ideas for the development of the semi-solid die-casting industry.

Abstract

一种连续半固态压铸生产方法，由中央控制器（1）控制执行以下内容：控制变质剂制备设备（2）生产固体变质剂以及将固体变质剂输送至半固态浆料制备设备（3）的具有液体浆料的制备容器中，控制半固态浆料制备设备生产半固态浆料以及将半固态浆料输送至半固态压铸机（4），控制半固态压铸机压铸；一种连续半固态压铸生产系统，包括变质剂制备设备、半固态浆料制备设备、半固态压铸机、中央控制器；该生产方法以及生产系统可以缩短制浆时间，提高浆料固体含量，使球状晶细化、圆整，提高半固态制浆的效率，稳定半固态浆料的质量，并实现半固态压铸生产一体化设备稳定生产。

Description

一种连续半固态压铸生产方法及生产系统
本申请要求在2016年04月08日提交中国专利局、申请号为201610216958.3、发明名称为“一种连续半固态压铸生产方法及生产系统”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本发明涉及半固态压铸生产领域，尤其涉及一种连续半固态压铸生产方法及生产系统。
背景技术
20世纪70年代初发展起来的半固态压铸技术，使传统压铸方式发生了深刻变化。国内外学者提出了许多半固态金属浆料制备工艺方法，如机械搅拌法、电磁搅拌法、控制凝固法、应变激活工艺、粉末冶金方法以及其他方法等。目前很多的半固态金属制浆方法存在：半固态浆料固液比难控制，制备的半固态浆料球状晶粗大，圆整度低。这些制浆方法受制浆设备效率和半固态浆料质量稳定性的影响，没有推广到工厂实际的连续压铸生产，还处在实验室研究阶段。
压铸行业半固态生产受制于制浆设备、制浆工艺及半固态浆料质量。上述制浆工艺的制浆设备复杂、制浆效率低，浆料固体含量不稳定，使一般的制浆工艺不能用于连续批量压铸生产。本发明的半固态浆料制备方法及连续压铸工艺解决了半固态压铸生产的高效、连续生产问题。
发明内容
为了解决上述技术问题，本发明提供了一种连续半固态压铸生产方法及生产系统，旨在提高半固态浆料制备效率、稳定半固态浆料质量，解决半固态连续压铸生产问题。
本发明提供的连续半固态压铸生产方法，包括：
由中央控制器控制执行以下内容：
控制变质剂制备设备生产固体变质剂以及将所述固体变质剂输送至半固态浆料制备设备的具有液体浆料的制备容器中；
控制所述半固态浆料制备设备生产半固态浆料以及将所述半固态浆料输送至半固态压铸 机；
控制所述半固态压铸机进行半固态压铸。
上述连续半固态压铸生产方法还可以具有以下特点：
所述控制变质剂制备设备生产固体变质剂以及将所述固体变质剂输送至半固态浆料制备设备的半固态浆料的制备容器包括以下步骤：
在变质剂锭加入电阻熔炉后，控制密封盖锁紧，控制所述电阻熔炉加热使变质剂锭成为温度为液体预设温度的液体变质剂，控制金属模具预热到并维持第一预设温度，控制所述液压装置关闭所述金属模具，控制升液管将所述液体变质剂注入所述金属模具，在生成固态变质剂后控制所述液压装置打开所述金属模具，将生成的固态变质剂通过固态变质剂输送装置输出至固态变质剂传输装置，所述液体预设温度为650～700摄氏度，所述第一预设温度的范围为180～240摄氏度。
上述连续半固态压铸生产方法还可以具有以下特点：
输送至半固态浆料制备设备的具有液体浆料的制备容器中的固态变质剂的质量为所述液态浆料的质量的0.5～1.5％。
上述连续半固态压铸生产方法还可以具有以下特点：
输送至半固态浆料制备设备的具有液体浆料的制备容器中的固态变质剂的质量为所述液态浆料的质量的1％。
上述连续半固态压铸生产方法还可以具有以下特点：
所述固体变质剂为中空半球形颗粒，每个颗粒的重量为10～20克。
上述连续半固态压铸生产方法还可以具有以下特点：
所述控制所述半固态浆料制备设备生产半固态浆料包括：控制气冷机械搅拌设备在所述制备容器内进行搅拌，以预设转速搅拌预设时长，通过所述空心搅拌棒的测温装置获取所述半固态浆料的温度，并控制所述制备容器的制备温度使所述半固态浆料的温度保持在第二预设温度；所述200～1000转每秒，所述预设时长为10～25秒，所述第二预设温度为595-605摄氏度。
上述连续半固态压铸生产方法还可以具有以下特点：
所述预设转速为800转每秒，所述预设时长为20秒，所述第二预设温度为605摄氏度。
本发明提供的连续半固态压铸生产系统，包括：变质剂制备设备、半固态浆料制备设备、半固态压铸机、中央控制器；
所述中央控制器，用于控制变质剂制备设备生产固体变质剂以及将所述固体变质剂输送至半固态浆料制备设备的具有液体浆料的制备容器中；控制所述半固态浆料制备设备生产半固态浆料以及将所述半固态浆料输送至半固态压铸机；控制所述半固态压铸机进行半固态压铸。
上述连续半固态压铸生产系统还可以具有以下特点：
所述变质剂制备设备包括电阻熔炉、密封盖、升液管、金属模具、液压装置、液压装置、固态变质剂输送装置；
所述中央控制器，用于根据下述方法控制变质剂制备设备生产固体变质剂以及将所述固体变质剂输送：在变质剂锭加入电阻熔炉后，控制密封盖锁紧，控制所述电阻熔炉加热使变质剂锭成为温度为液体预设温度的液体变质剂，控制金属模具预热到并维持第一预设温度，控制所述液压装置关闭所述金属模具，控制升液管将所述液体变质剂注入所述金属模具，在生成固态变质剂后控制所述液压装置打开所述金属模具，将生成的固态变质剂通过固态变质剂输送装置输出至固态变质剂传输装置，所述液体预设温度为650～700摄氏度，所述第一预设温度的范围为180～240摄氏度。
上述连续半固态压铸生产系统还可以具有以下特点：
所述半固态浆料制备设备包括内置套铜管的空心搅拌棒以及制备容器；所述空心搅拌棒内设置有测温装置；
所述中央控制器，用于控制气冷机械搅拌设备在所述制备容器内进行搅拌，以预设转速搅拌预设时长，通过所述空心搅拌棒的测温装置获取所述半固态浆料的温度，并控制所述制备容器的制备温度使所述半固态浆料的温度保持在第二预设温度，所述200～1000转每秒，所述预设时长为10～25秒，所述第二预设温度为595-605摄氏度。
本发明提供的连续半固态压铸生产工艺，具有以下有益效果：
(1)通过在液体浆料中加入固体变质剂，同时控制变质剂的加入百分比以及与变质剂与液体浆料的相对温度，使得液体浆料能够快速降温，固体变质剂在搅拌过程中熔化分解形成大量固体形核，使由搅拌打碎的树枝晶快速形成细小圆整的球状晶组织，并将最终形成的半固态浆料中浆料固体的含量提高并一直稳定在在42～50％左右。缩短了制浆时间，提高了浆料 固体含量，使球状晶细化、圆整，解决了常规半固态浆料制备过程固体含量偏低的问题，从而提高了半固态制浆的效率，稳定了半固态浆料的质量。
(2)实现固体变质剂制备、半固态浆料制备、半固态浆料压铸这三个步骤的联动循环运行，实现了半固态压铸生产一体化设备自动稳定生产。生产的半固态压铸件的内部质量稳定，合格率提高，降低了生产成本。一体化设备连续循环进行半固态压铸工艺方法开拓了半固态压铸生产的新模式，为半固态压铸行业的发展提供了新的思路。
附图说明
图1是本发明中连续半固态压铸生产系统的结构图；
图2是本发明中连续半固态压铸生产方法的流程图；
图3是使用本发明的方法生产的半固态浆料的金相组织示图。
附图标识：中央控制器1，变质剂制备设备2，电阻熔炉201，密封盖202，升液管203，金属模具204，液压装置205，固态变质剂输送装置206，半固态浆料制备设备3，气冷机械搅拌设备301，制备容器302，半固态压铸机4。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。需要说明的是，在不冲突的情况下，本申请中的实施例及实施例中的特征可以相互任意组合。
图1是本发明中连续半固态压铸生产系统的结构图，此生产系统包括：中央控制器1以及均与中央控制器电信号连接的变质剂制备设备2、半固态浆料制备设备3、半固态压铸机4。其中，中央控制器1控制整个生产流程，各过程动作通过数控程序和相应的感应位置开关自动循环完成连续的压铸生产。
中央控制器1控制变质剂制备设备2生产固体变质剂以及将固体变质剂输送至半固态浆料制备设备3的具有液体浆料的制备容器中；控制半固态浆料制备设备3生产半固态浆料以及将半固态浆料输送至半固态压铸机4；控制半固态压铸机4进行半固态压铸。
变质剂制备设备2包括电阻熔炉201、密封盖202、升液管203、金属模具204、液压装置205、固态变质剂输送装置206。中央控制器1根据下述方法控制变质剂制备设备2生产固体变质剂以及将固体变质剂输送：在变质剂锭加入电阻熔炉201后，控制密封盖202锁紧，控制电阻熔炉201加热使变质剂锭成为温度为液体预设温度的液体变质剂，控制金属模具204预热到并维持第一预设温度，控制液压装置205关闭金属模具204，控制升液管203将液体变质剂注入金属模具204，在生成固态变质剂后控制液压装置205打开金属模具204，将生成的固态变质剂通过固态变质剂输送装置206输出至固态变质剂传输装置，其中，液体预设温度为650～700摄氏度，第一预设温度的范围为180～240摄氏度。金属模具204包括上膜腔和下膜腔，通过液压装置205控制金属模具204开模后，上模腔可在丝杠的传送下运行至制浆区域，并将固体变质剂传输至固态变质剂输送装置206。
半固态浆料制备设备3包括气冷机械搅拌设备301和制备容器302；空心搅拌棒301内设置有测温装置。气冷机械搅拌设备301包括内置铜管的空心搅拌棒，搅拌棒转动时一定流量和压力的压缩空气间接和铝液进行热交换，起到铝液降温的作用。其中，设置气冷机械搅拌设备时，优选的设置为冷却空气压力为3.5～4.5KPa，压缩空气流量为10～30L/min。
中央控制器1控制气冷机械搅拌设备301在制备容器内进行搅拌，以预设转速搅拌预设时长，通过空心搅拌棒的测温装置获取半固态浆料的温度，并控制制备容器的制备温度使半固态浆料的温度保持在第二预设温度，并且保持第二预设温度的变动范围在±3摄氏度的偏差范围。预设转速为200～1000转每秒，预设时长为10～25秒，第二预设温度为595-605摄氏度。
图2是连续半固态压铸生产工艺的流程图。本方法包括：由中央控制器控制执行以下内容：
步骤1，控制变质剂制备设备生产固体变质剂以及将固体变质剂输送至半固态浆料制备设备的具有液体浆料的制备容器中；
步骤2，控制半固态浆料制备设备生产半固态浆料以及将半固态浆料输送至半固态压铸机；
步骤3，控制半固态压铸机进行半固态压铸。
下面详细说明本方法。
步骤1中，在变质剂锭加入电阻熔炉后，控制密封盖锁紧，控制电阻熔炉加热使变质剂锭成为温度为液体预设温度的液体变质剂，控制金属模具预热到并维持第一预设温度，控制 液压装置打开金属模具，控制升液管将液体变质剂注入金属模具，控制液压装置关闭金属模具，在生成固态变质剂后控制液压装置打开金属模具，将生成的固态变质剂通过固态变质剂输送装置(可以为流槽)输出至固态变质剂传输装置。其中，液体预设温度为650～700摄氏度，优选为680摄氏度，第一预设温度的范围为180-240摄氏度。将控制金属模具预热到并维持180-240摄氏度，可以使变质剂颗粒保持在80～120摄氏度，将制浆时加入的中空半球形变质剂颗粒很容易熔化形成固体形核，温度保持在80～120度的变质剂颗粒在制浆过程中能起到快速降温的目的。
输送至半固态浆料制备设备的具有液体浆料的制备容器中的固态变质剂的质量为液态浆料的质量的0.2～1.5％。变质剂加入量对球状晶的圆整度和固体含量有一定影响，如表1所示。
表1 固体变质剂颗粒加入量对球状晶圆整度和固体含量的影响
Figure PCTCN2017077539-appb-000001
由表1可知，在变质剂加入量在0.5～1.5％范围内，随着加入量增加，半固态浆料的球状晶趋于圆整，固体含量比例增加，当加入量大于1％后，浆料固体含量又降低，圆整度变差。固态变质剂颗粒最佳加入量是制浆合金量的1％。
固体变质剂为中空半球形颗粒，每个颗粒的重量为10～20克。
步骤2中，控制半固态浆料制备设备生产半固态浆料包括：控制气冷机械搅拌设备在制 备容器内进行搅拌，以预设转速搅拌预设时长，通过空心搅拌棒的测温装置获取半固态浆料的温度，并控制制备容器的制备温度使半固态浆料的温度保持在第二预设温度；预设转速为200～1000转每秒，预设时长为10～25秒，第二预设温度为595-605摄氏度。
搅拌棒转速和搅拌时间对半固态铸件的球状晶组织和学能性能有一定的影响，如表2所示。
附表2 搅拌速度与搅拌时间对半固态产品力学性能的影响
Figure PCTCN2017077539-appb-000002
从表2的实验数据可以看出，制浆时搅拌棒的搅拌速度和搅拌时间对半固态压铸产品的力学性能有直接影响。当保温炉铝液温度在670摄氏度时搅拌制浆，制浆参数：转速800转每秒，搅拌20s，半固态浆料温度为605摄氏度，该参数半固态浆料压铸生产的半固态产品性能较佳。
随着搅拌速度的增加，半固态铸件组织中初生固相的形貌逐渐趋于细小圆整，分布更加均匀。其主要原因在于：(a)增加搅拌速度，有利于提高熔体在坩埚内的对流强度，对流强度的增大可以促使合金熔体在相同的时间内达到更大的过冷度，从而更易形核，同时增大对流强度可以促使过冷的合金熔体内部温度场和浓度场的分布更加均匀一致；(b)当搅拌速度较小时，枝晶与搅拌叶片、枝晶与筒壁、以及枝晶与枝晶之间碰撞的次数和强度不够，仅有部分枝晶被打碎。随着搅拌速度的提高，碰撞强度和频率将会大大增加，有利于枝晶臂折断,同时有利于颗粒状晶粒尖角处的磨圆，从而转变为近球状晶粒。但是，剧烈的搅拌速度会造成合金熔体卷气严重，导致组织中存在较多的气孔缺陷，不利于成形件性能的提高。
图3是本发明中生产的半固态浆料的金相组织示图。
本发明具有以下有益效果：
(1)通过在液体浆料中加入固体变质剂，同时控制变质剂的加入百分比以及与变质剂与液体浆料的相对温度，使得液体浆料能够快速降温，固体变质剂在搅拌过程中熔化分解形成大量固体形核，使由搅拌打碎的树枝晶快速形成细小圆整的球状晶组织，并将最终形成的半固态浆料中浆料固体的含量提高并一直稳定在42～50％左右。缩短了制浆时间，提高了浆料固体含量，使球状晶细化、圆整，解决了常规半固态浆料制备过程固体含量偏低的问题，从而提高了半固态制浆的效率，稳定了半固态浆料的质量。
(2)实现固体变质剂制备、半固态浆料制备、半固态浆料压铸这三个步骤的联动循环运行，实现了半固态压铸生产一体化设备自动稳定生产。生产的半固态压铸件的内部质量稳定，合格率提高，降低了生产成本。一体化设备连续循环进行半固态压铸工艺方法开拓了半固态压铸生产的新模式，为半固态压铸行业的发展提供了新的思路。
需要说明的是，在本文中，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的物品或者设备不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种物品或者设备所固有的要素。在没有更多限制的情况下，由语句“包括……”限定的要素，并不排除在包括所述要素的物品或者设备中还存在另外的相同要素。
以上实施例仅用以说明本发明的技术方案而非限制，仅仅参照较佳实施例对本发明进行了详细说明。本领域的普通技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本发明技术方案的精神和范围，均应涵盖在本发明的权利要求范围当中。
工业实用性
本发明的连续半固态压铸生产方法缩短了制浆时间，提高了浆料固体含量，使球状晶细化、圆整，解决了常规半固态浆料制备过程固体含量偏低的问题，从而提高了半固态制浆的效率，稳定了半固态浆料的质量；其生产系统实现固体变质剂制备、半固态浆料制备、半固态浆料压铸这三个步骤的联动循环运行，实现了半固态压铸生产一体化设备自动稳定生产。生产的半固态压铸件的内部质量稳定，合格率提高，降低了生产成本。一体化设备连续循环进行半固态压铸工艺方法开拓了半固态压铸生产的新模式，为半固态压铸行业的发展提供了新的思路。

Claims (10)

  1. 一种连续半固态压铸生产方法，其特征在于，包括：
    由中央控制器控制执行以下内容：
    控制变质剂制备设备生产固体变质剂以及将所述固体变质剂输送至半固态浆料制备设备的具有液体浆料的制备容器中；
    控制所述半固态浆料制备设备生产半固态浆料以及将所述半固态浆料输送至半固态压铸机；
    控制所述半固态压铸机进行半固态压铸。
  2. 如权利要求1所述的连续半固态压铸生产方法，其特征在于，所述控制变质剂制备设备生产固体变质剂以及将所述固体变质剂输送至半固态浆料制备设备的半固态浆料的制备容器包括以下步骤：
    在变质剂锭加入电阻熔炉后，控制密封盖锁紧，控制所述电阻熔炉加热使变质剂锭成为温度为液体预设温度的液体变质剂，控制金属模具预热到并维持第一预设温度，控制所述液压装置关闭所述金属模具，控制升液管将所述液体变质剂注入所述金属模具，在生成固态变质剂后控制所述液压装置打开所述金属模具，将生成的固态变质剂通过固态变质剂输送装置输出至固态变质剂传输装置，所述液体预设温度为650～700摄氏度，所述第一预设温度的范围为180～240摄氏度。
  3. 如权利要求1所述的连续半固态压铸生产方法，其特征在于
    输送至半固态浆料制备设备的具有液体浆料的制备容器中的固态变质剂的质量为所述液态浆料的质量的0.5～1.5％。
  4. 如权利要求3所述的连续半固态压铸生产方法，其特征在于
    输送至半固态浆料制备设备的具有液体浆料的制备容器中的固态变质剂的质量为所述液态浆料的质量的1％。
  5. 如权利要求1所述的连续半固态压铸生产方法，其特征在于
    所述固体变质剂为中空半球形颗粒，每个颗粒的重量为10～20克。
  6. 如权利要求1所述的连续半固态压铸生产方法，其特征在于，
    所述控制所述半固态浆料制备设备生产半固态浆料包括：控制气冷机械搅拌设备在所述制备容器内进行搅拌，以预设转速搅拌预设时长，通过所述空心搅拌棒的测温装置获取所述半固态浆料的温度，并控制所述制备容器的制备温度使所述半固态浆料的温度保持在第二预设温度；所述200～1000转每秒，所述预设时长为10～25秒，所述第二预设温度为595-605摄 氏度。
  7. 如权利要求6所述的连续半固态压铸生产方法，其特征在于，
    所述预设转速为800转每秒，所述预设时长为20秒，所述第二预设温度为605摄氏度。
  8. 一种连续半固态压铸生产系统，其特征在于，包括：变质剂制备设备、半固态浆料制备设备、半固态压铸机、中央控制器；
    所述中央控制器，用于控制变质剂制备设备生产固体变质剂以及将所述固体变质剂输送至半固态浆料制备设备的具有液体浆料的制备容器中；控制所述半固态浆料制备设备生产半固态浆料以及将所述半固态浆料输送至半固态压铸机；控制所述半固态压铸机进行半固态压铸。
  9. 如权利要求8所述的连续半固态压铸生产系统，其特征在于，
    所述变质剂制备设备包括电阻熔炉、密封盖、升液管、金属模具、液压装置、液压装置、固态变质剂输送装置；
    所述中央控制器，用于根据下述方法控制变质剂制备设备生产固体变质剂以及将所述固体变质剂输送：在变质剂锭加入电阻熔炉后，控制密封盖锁紧，控制所述电阻熔炉加热使变质剂锭成为温度为液体预设温度的液体变质剂，控制金属模具预热到并维持第一预设温度，控制所述液压装置关闭所述金属模具，控制升液管将所述液体变质剂注入所述金属模具，在生成固态变质剂后控制所述液压装置打开所述金属模具，将生成的固态变质剂通过固态变质剂输送装置输出至固态变质剂传输装置，所述液体预设温度为650～700摄氏度，所述第一预设温度的范围为180～240摄氏度。
  10. 如权利要求8所述的连续半固态压铸生产系统，其特征在于，
    所述半固态浆料制备设备包括内置套铜管的空心搅拌棒以及制备容器；所述空心搅拌棒内设置有测温装置；
    所述中央控制器，用于控制气冷机械搅拌设备在所述制备容器内进行搅拌，以预设转速搅拌预设时长，通过所述空心搅拌棒的测温装置获取所述半固态浆料的温度，并控制所述制备容器的制备温度使所述半固态浆料的温度保持在第二预设温度，所述200～1000转每秒，所述预设时长为10～25秒，所述第二预设温度为595-605摄氏度。
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